Reliability Testing of MWD Assemblies Developing a Standard

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Terence Clark
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1 Reliability Testing of MWD Assemblies Developing a Standard I.A.D.D. Forum Thursday, September 29, 2016 Presented by: Bob Joyce

2 Questions One Must Ask?? Why is there no standard or best practice? Can we develop guidelines for testing: Board and sensor level qualification? Sub-assembly level qualification? Production Screens? Transportation Qualification? Can standards be developed for various classes of technology? Is there sufficient testing performed at the various development and production stages??

3 Environmental Tests Electrical Function Temperature Temp with Vibe Shock Pressure Flow Loop

4 Sample of Existing Test Standards Component level testing/batteries MIL-STD-883H (vibe), MIL-STD-202G 9(all), IEEE UN Testing for Lithium Batteries Sub-Assembly level testing for Downhole NO Governing Standard for Qualification Navmat P-9492: Manufacturing Screen (Thermal & Vibe) MIL-STD-810G: General all encompassing for qualifying products MIL-STD-167: Vibration only standard IEC : General Spec (Inter. Electrotechnical Comm) ASTM-D4160: Shipping (Amer. Society for Testing & Materials) ISTA-2A: Packages (Inter. Safe Transit Assoc.)

5 Common Practices Thermal Testing Burn-In Dwell Time = max. downhole dwell time Soak Temp = Targeted spec (add 10 o -15 o C) Thermal Cycles Lower SP = coldest environment possible (subtract 10 o -15 o C) Upper SP = same as Burn-In Ramp Rates = 15 o -20 o C/min. (lower if sensitive sensors involved) Number of Cycles = Life Testing Combination of above As many as days Models available to predict MTBF

6 Accelerated Life Tests - HALT Common Practice Engineering prototype phase Method to determine weaknesses in design Present product as exposed as possible Destructive test Thermal & vibe Typhoon4 Inferno Chamber Temperature: -100 o C to +250 o C Vibration: Up to 85 G rms

7 Temperature ( C) HALT Highly Accelerated Life Test Determine Lower Functional Limit Cold Step Stress Test Time (min.)

8 Temperature ( C) HALT Highly Accelerated Life Test Hot Step Stress Test Time (min.) Determine Upper Functional Limit

9 Vibration (Grms) Temperature ( C) Rapid Thermal Cycling HALT Test Time (min.) Vibration Step Stress Test Time (minutes)

10 Temperature ( C) Vibration (Grms) HALT Combined Environment Temperature Vibration Test Time (min.)

11 HALT Testing MWD Probe Diagnostics Multiple Potted PCB s Customer Monitoring a HALT Inaert board test Powered PCB s unpotted

12 Modified HALT Programs 10 Cycles Product Temp: -40 o C to +150 o C Vibe: Constant 50 G rms Dwell Time: 15 min. Transitions: ~60 o C/min.

13 Typical Vibe Test Test Articles: Electro-Mechanical Sub-Assemblies Desired Temp Ratings: 150 o C to 185 o C (200 o C) Qualification: Verify performance simulating downhole drilling conditions. (Vibe, Shock, Temp) Insert pic of MWD tool

14 Vibration Sources - Drilling Stick Slip Bit Bounce (displ.) Forward Whirl Bit Bounce (axial) BHA Whirl Stabilizers Bit (cones/blades) Whirl (backward) Mud Motors Bit (inserts) Tortional Resonance Tortional Bit Chatter Bit Bounce (impact) Ave. Amplitude = G I I I I Frequency (Hz)

15 Fixturing/Orientation Z Axis X Axis Rotate 90 for Y

16 Accel Placement Insert Pics Large 3 axis, fixture accel

17 Vibration Sine Sweeps

18 Displacement (mm p-p) Displacement (mm p-p) Sine HOLD Test 3mm Disp. 7 Displacement Profile Demand Frequency (Hz) Displacement vs. Time X-Axis Control Demand Time (min) X-Axis Control Jan 21, :10:27 Demand: 3 mm Control Disp: mm Control G: G Total Time: 0:05:51 End of Timed Test 1-Sine Hold 3mm X-Axis S/N SMA-0200

19 Vibration Sine Sweeps Common Practice Sweep Hz 1 G peak Sine input (X, Y & Z axes) Resonance Test 5-20 G peak Sine input (X, Y & Z axes) Qual Test 1 Oct./min. sweep speed Check resonance of entire system including fixtures Measure transmissibility of key locations on UUT Dwell on highest resonance for minutes

(200 o C) Qualification: Verify performance simulating

20 Typical Vibe Test Test Articles: Electro-Mechanical Sub-Assemblies Desired Temp Ratings: 150 o C to 185 o C (200 o C) Qualification: Verify performance simulating downhole drilling conditions. (Vibe, Shock, Temp) Insert pic of MWD tool

21 Vibration Sine Sweeps Common Practice Sweep Hz 1 G peak Sine input (X, Y & Z axes) Resonance Test 5-20 G peak Sine input (X, Y & Z axes) Qual Test 1 Oct./min. sweep speed Check resonance of entire system including fixtures Measure transmissibility of key locations on UUT Dwell on highest resonance for minutes

22 Vibration Random Common Practice Freq: Hz G rms Various profiles for different applications Run Random profile for minutes

23 20G Random Vibe

24 Acceleration Spectral Density (G²/Hz) Random Vibe - Transport 0.75 G rms Acceleration Spectral Density 1x10-2 1x10-3 1x10-4 1x10-5 Demand Control Frequency (Hz) 300 Feb 06, :57:50 Level 1) 100 % Output: Volts RMS ASTM D4169 D4728B Mod 300Hz G 1 hour Demand: G RMS Level Time: 1:00:00 Rosemount Analytical Model 370XA Chromatograph Control: G RMS Total Time: 1:00:20 End of Test S/N

25 4G Random Transportation Qual

26 Vibration Test Plan QUAL TRANSPORT Freq (Hz.) Sine Ampl (g) 5 1 Speed (oct/min) 1 3 Random Ampl (g) At times Vibe tests requested at Temp

27 Shake & Bake

28 Shaker Vibe vs HALT Vibe 6DOF Vibe Excitation Hz. G rms level controlled

29 Classic Shock 50 Gpeak

Free Fall or Pneumatic Shock Testing Common Practice ½ Sine input (X, Y & Z axes) # Shocks Variable (10-200) Larger Assemblies 10 50 G

30 Free Fall or Pneumatic Shock Testing Common Practice ½ Sine input (X, Y & Z axes) # Shocks Variable (10-200) Larger Assemblies G peak (Transport/Screens) G peak (Quals) Pulse Width: msec. Smaller Assemblies/PCB s G peak Pulse Width: ½ -2 msec.

31 The Toughness of Shock Tests

32 Flow Loop Testing

33 Snubber Performance Study

34 Snubber Performance - Shock 1100 G 550 G

35 Diagnostics Screen

36 Summary There are no governing test specs for downhole sub-assemblies across the industry There are common and somewhat accepted practices for testing but with broad limits OEM s and large service companies vary in their approach to testing. (time to market, budgets) There is no doubt that a Best Practice plan will contribute to lowering those warranty costs Independent labs like DynaQual are very interested in helping to develop test standards for the industry

37 Thank You

CENTROTECNICA S.r.l. Centrotecnica Test House

CENTROTECNICA S.r.l. Centrotecnica Test House Centrotecnica Test House Environmental Testing Lab - Our capabilities Centrotecnica Test House Enrvironmental Testing Lab - Our capabilities For Vibration and Shock Testing Name of the equipment Rated